Distribution Panels CXDM-E2 User Manual
Contents
1. 12 51 sam s 6 00 MID MOUNT 3 2X 1 25 0 0 0 2 1 REVISIONS LTR DESCRIPTION DWN DATE CHK E D C 18 25 i i CH ES 0 24 0200170 003 UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES XX 0 040 XXX 0 020 X XXX 0 010 ANGULAR 1 APPROVALS oae E A INTERPRET DIM AND TOL PER OUTLINE DRAWING ASME Y14 5 1994 L CHECKED DM 2015 06 24 CKDM EZ THIRD ANGLE PROJECTION E ll SIZE DWG NO REV 0200170 06 Sei Hz npe Tea 2 1 DO NOT SCALE DRAWING LU A J Ob CO OCH Jo De l0 N 9 9 kama 0 N X ES O Z 99 oF a l SS _ 09600009 O O O O O O O O O O s e e 9 o SU O O O O O O O O 0 O Q 9 9 O O O O O O O O O O O O O O O O O O O O O O O O 060009809680 O O O O O O O O O O G O O O O O O O O O O O O 0000086669 0000000000 O 9 O O O O O O O O O O O O O O 0 6 8 9 O O O O O O O O O O 9 O O O O O O O O O O O O O O G 9 O O O O O O O O O O O O O O 9 O j 0000000000 O O O O O O O O O O O O O O O O O O O O 0 O O O O O O O O O O e 0O O 9 9 O O O O O O O O O O O2. To Ground Stud on Panel 8700829 001 To Ground Stud on side panel E2 E3 Indicator BoardB SIDE B RIGHT SIDE FACING FRONT CUSTOMER CONNECTIONS CHASSIS Connection through mounting screw J PWR_B VB_SNS I LIST 712 or 7 CABLE HARNI L ADIO with cordex HP CXC HP L ADIO GND To Ground Stud on Panel 8700790 001 B ALMB gt gt Le ALMB VB VB VB VB VB_SNS VB_SNS _ BRKR_B_ALM PWR_B PWR_B 4 VB_SNS VBSNS _ 8700789 001 B RED wire for 48V 24V BLACK wire for 48V 24V 8700766 001 B RED wire for 48V 424V BLACK wire for 48V 24V J ALMA ALMA BRKR_B_ALM PWR_B VB_SNS V ENSE E2 Alarm Strip 19 22 Pos RIGHT SIDE FACING FRONT S a S a D TB407 3 67 TB408 2 65 TB408 3 64 TB410 3 76 TB411 3 73 TB406 1 72 TB400 3 10 TB400 1 12 TB405 3 13 TB405 2 14 TB405 1 15 TB404 3 16 TB404 2 17 TB404 1 18 RETURN FEED B TB200 1 63 TB200 2 62 TB205 1 61 TB205 2 60 TB502 2 22 TB502 1 23 4 J VB_SNS VB_SNS VA_SNS VA_SNS TB202 1 59 TB202 2 58 TB200 1 57 TB200 2 56 TB306 1 55 TB306 2 54 TB305 1 53 TB305 2 52 TB302 1 51 TB302 2 50 TB300 1 49 TB300 2 48 TB305 1 47 SIS SIE a S SIE SIN SIN 2 ae pdha pdhal Ka Ki hM sis sls 3 3 alg 313 S S3 l
3. 2 Turn the breaker OFF 3 Orient the breaker so that the actuator is to the right with the breaker in the OFF position Actuator Align the breaker terminals with the correct holes Carefully push the breaker into position Ensure that the breaker is fully inserted so that the flat face of the hexagonal nut is against the mounting surface 9400011 JO Rev A 19 7 Wiring This chapter provides cabling details and notes on cable sizing for DC applications All field wired conductors shall be rated to a minimum 90 C Bead WARNING Ensure that the power is removed by turning off rectifiers and removing battery line fuses or connections before attempting work on the wiring connections Use a volt meter to verify the absence of voltages Clearly mark the correct polarity of the battery leads before working on DC connections Refer to the Chapter 6 Installation for safety precautions and tools required 7 1 Chassis Ground The E2 frame must be connected to the Main Ground Bus MGB or Frame Ground Bus FGB for safety rea sons and to meet standard Telco grounding requirements This acts as a system reference and a low impedance ground path for surges transients and noise The FGB or MGB should have a direct low impedance path to the building grounding system The cable from the distribution center to the MGB should be sized to provide sufficient ampacity to clear the largest fuse or breaker on the distribution
4. 7 7 Network and Remote Communication When equip ped with a CXC HP controller the system can be set up monitored and tested via an Ethernet 10 100 Base T serial data connection and accessed via the controller or a web interface Pin outs are shown in the customer connections drawing Some standard scenarios are described below e Network Connection The Ethernet port is designed to connect the controller to a user supplied network TCP IP supplied by the user via a front panel RJ 45 jack Use a standard network cable for this connection e Local Connection The Ethernet port can also be used for local access such as using a laptop computer Use a standard Ethernet cable for this connection 7 8 Signal Wiring Connections for Controller Reference is made to drawings located at the rear of this manual Custom configurations may be detailed within the Innovative Energies documentation package For terminal block connections the recommended wire sizes are 16 26 AWG 1 5 0 129 mmP2P for the tem perature range of 0 50 C as per UL CSA Bundle the signal cables together and route them through the entry holes of the shelf 7 8 1 Alarm Outputs Terminals provide contacts for extending various alarm or control signals Each relay output can be wired for NO or NC operation during an alarm or control condition Relays can be programmed to energize or de energize during an alarm condition See the controller software manual All re
5. The above information is valid at the time of publication Consult factory for up to date ordering information Specifications are subject to change without notice Can accept up to 2x 750 MCM cables back to back on hot and return connections Vertical input kit is highly recommended when each bus is fused at 400A and above For vertical input connections order kit For double pole breakers order adapter kit For triple pole breakers order adapter kit For ordering information refer to datasheet 0470195 001 9400011 JO Rev A 4 Features 4 1 Ground Connection Each side panel of the E2 has a lug landing for connection to earth ground These may either be horizontally aligned PEM studs Figure 2 or vertically aligned PEM nuts for use with 3 8 bolts included with system The E2 grounds can either be connected to the frame in which the E2 is mounted if the frame is grounded or they can be connected directly to the ground bar in a remote location Both connections must be made A mini mum 6 AWG wire is recommended Follow all local codes and company safety protocols for the ground connections The above information should be used as a guide only Left Ground Connection Right Ground Connection Figure 2 Ground Connections 4 2 Feed Connection The E2 has two isolated hot and return input feeds Each bus each can accommodate up to two 2 750MCM cables max lug tongue width is 1 63 inches in a back to b
6. innovative energies Installation amp Operation Manual Part 9400011 JO Effective 06 2015 Innovative Energies Ltd 1 Heremai Street Henderson NZ Tel 64 9 835 0700 info innovative co nz www innovative co nz CXDM E2 Series Distribution Module 600A NOTE Photographs contained in this manual are for illustrative purposes only These photo graphs may not match your installation NOTE Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding If there are questions regarding the safe operation of this powering system S NOTE IE shall not be held liable for any damage or injury involving its enclosures power supplies generators batteries or other hardware if used or operated in any manner or subject to any condition inconsistent with its intended purpose or if installed or oper ated in an unapproved manner or improperly maintained For technical support contact IE Technologies Phone 64 9 835 0700 Innovative Energies Ltd 1 Heremai Street Henderson NZ Tel 64 9 835 0700 info innovative co nz www innovative co nz 9400011 J0 Rev A Table of Contents Lita 5 Weed Sale a MONS elia 5 1 2 General Warning and Leen 5 1 3 Done EE 6 1 4 Battery Safety EE 6 Lc Na 7 2 ledere 7 2 2 ln Le RE UE 7 Ee EE 8 di EE 9 AT Ground Connection EE 9 42 Re 9 43 Eoad OMIM allea aa 10 4 4 Monitoring Methods E 11 45 Standard Front E 11 4 6 Front
7. e Various crimping tools and dies to match lugs used in installation e Digital voltmeter equipped with test leads e Cable cutters e Torque wrench 1 4 drive O 150 in lb e Torque wrench 3 8 drive O 100 ft lb e Insulating canvases as required 2 x 2 1 x 1 3 x 3 etc e Various insulated hand tools including Combination wrenches Ratchet and socket set Various screwdrivers Electricians knife e Cutters and wire strippers 14 to 22 AWG 2 5 to 0 34 mm 6 3 Assembly and Mounting The E2 must be mounted in a clean and dry environment Sufficient free space must be provided at the front and rear of the power system in order to meet the cooling requirements and to allow easy access to the power system components This includes at least 2RU 3 5 of space above the unit to access connections points and provide adequate cooling ventilation Attach the power system to the customer provided relay rack using mounting screws and star washers This will ensure an electrical bond between the system chassis and relay rack The system may be mounted into a 19 rack in a center mount position Use the 19 to 23 rack adaptors to mount into a 23 rack The unit is shipped with the mounting brackets in the front mounted position Move them to the center position as desired and attach 19 23 the rack adapters when installed in a 23 rack 9400011 J0 Rev A 6 4 Breaker Installation 1 Ensure mid trip breakers are used for load
8. Monitoring 2 Breaker Alarm Monitoring 2 Expansion UO Customer Use Temperature Sensor Inputs 4 Form C Relay Outputs 12 Digital Inputs 6 Voltage Sense Inputs 2 Current Shunt Inputs 4 CXC HP Controller Local connection to LADIO Advanced GUI Ethernet Connection 4 4 1 Breaker Labelling The breakers are numbered starting from one near the side panel and going up to 11 near the center line The labels for the Bus A breakers are indicated by black letters and the labels for Bus B are indicated by white letters on a black background The breaker position index label is a thin strip over the breakers and is visible from the front while the breaker assignment label is located on the top of the front panel and has additional space for describing the use of the breaker This label is visible from the front when the door is open as well as from the top when the door is closed 4 5 Standard Front Panel Breaker Index Labels VE Breaker Assignment Labels Figure5 Breaker Labelling 9400011 J0 RevA 11 Alarm COM Bus A Breaker e 12 4 5 1 Status Indicators All E2 systems are equipped with two LED status indicators on the front panel which indicate the status of a single bus Bus A on the left LED and Bus Bon the right The LED s indicate the following e Power Green Power to the bus e Alarm Red Breaker tripped 4 5 2 Basic Status Outputs Each indicator board has t
9. O O O O O O O O O O se oc 9 O e Olj O O O O O O O O 0 O Q 0 O O O O O O O O O O O O C O O O O O O O O O O O O O O 9 e e e e O O O O O O O O O O 9 O O O O O O O O O O O O 096600890660 O O O O O O O O O O o oi E098000606SO O O O O O O O O O O Di e o 9 0 O lj O O O O O O O O O 0 KN 0060006060 O O O O O O O O O O R ES Q O O O O O O O O O O O O O O O O O O O O O 000009409060 O O O O O O O O O O 0000866660 O O O O O O O O O O 069000920900 O O O O O O O O O O O se O e 0 6 SJ 0000000000 9 O O O O O O O O O O O 900900090020 O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O 0000066666 O O O O O O O O O O O O O O O O O O O O O O O O O 0 6 9 O O O O O O O O O O O O O O O O O O O O O O O O 009600062860 0000000000 O O O 9 9 O O O O O O O O O O O 00600006090960 O O O O O O O O O O O O O O O O O O O O 0900090060 O O O O O O O O O O 0O 0 9 9 O O O O O O O O O O 9 O O O O O O O O O O O0 see O 6 OL j O O O O O O O O O O 06600080980 O O O O O O O O O O O O O O O O O O0 0 LI KE CH N N LLI n 0 80 18 25 5 29 19 00 3 47 0200170 013 0 24 02
10. Panel with Enhanced Osio 12 4 7 Front Panel with a CXC HP Controller aaa aaaa eaaa eaaa aaa Ek kk kek kk EEN 14 5 Site Evaluation and Pre Installation 0n aa erssaoonn eea aee nana nana nana km kk kk kk 17 o PACING Maten A leali 17 5 2 Run EEN 17 5 3 General Receipt ot SMIPMEN rene EENG 17 6 idoneo 18 GN ONE 18 62 TOONS FAC QUIN Orern ard keyd agan a ne kad Pak Ka ba VERE A K N a aaa 18 6 3 EE EIERE 18 6 4 Breaker Installation rara bea a la kal nala bl kaa aga nd a aa a aja aa b x aha del 19 9400011 J0 RevA Za WINO E 20 Jal Chassis Ground EE 20 7 2 Calculating output wire size requirements ii 21 7 3 DG Output CONNGGIONS sanan earlier 21 gek Distribution GADING sasaka aas aaa etre ected ka a GE ag aa a a aa ag anaa e henen a GAN io a 25 45 Alamanni Signal MOT OI E 26 7 5 GAN Serial POMS EE 27 7 7 Network and Remote Communication eses eea eaaa aaa eaaa aana a 27 7 8 Signal Wiring Connections eu ET 27 8 Malato 29 9 Warranty and Service Information EE 30 9 11 Technical Support EN 30 de Waranty ces ccc a aaa an a Ane E a es em 30 9 3 Retum of Material relati 30 9 4 Service CEMOlS iii Ri 30 10 Acronyms amd DEN 31 T e e E 32 9400011 J0 Rev A 1 Safety SAVE TH ESE INSTRUCTIONS This manual contains important safety instructions that must be followed during the installation servicing and maintenance of the product Keep it in a
11. and locked out before performing any installation or removal procedure Ensure that no liquids or wet clothes come into contact with internal components Hazardous electrically live parts inside this unit are energized from the batteries even when the AC input power is disconnected The enclosure which contains the DC or AC power system along with customer installed radios must remain locked at all times except when authorized service personnel are present Always assume electrical connections or conductors are live Turn off all circuit breakers and double check with a voltmeter before performing installation or maintenance Place a warning label on the utility panel to warn emergency personnel that a reserve battery source is present which will power the loads in a power outage condition or if the AC disconnect breaker is turned off At high ambient temperature conditions the internal temperature can be hot so use caution when touch ing the equipment 1 4 Battery Safety e Servicing and connection of batteries must be performed by or under the direct supervision of person nel knowledgeable of batteries and the required safety precautions e Always wear eye protection rubber gloves and a protective vest when working near batteries Remove all metallic objects from your hands and neck e Use OSHA approved insulated hand tools Do not rest tools on top of batteries e Batteries contain or emit chemicals known to cause cancer and birth
12. center excluding the battery protection fuse or circuit breaker This is the minimum requirement other factors including length of cable and special grounding requirements of the load should also be factored in The insulated cable should be equipped with two hole crimp type lugs and should not have any tight bends or kinks Use the two studs shown in Figure 11 to connect the chassis ground of the E2 to the building MGB Recom mended wire size is a Minimum of 6 AWG insulated cable The above should be used as a guide follow local codes and company safety protocols for the ground connec tions Left Ground Connection Right Ground Connection Figure 11 Ground connections horizontal alignment shown 20 9400011 JO Rev A 7 2 Calculating output wire size requirements To calculate wire sizes first determine the appropriate maximum voltage drop requirement Use the formula be low to calculate the CMA wire size requirement Determine the size and number of conductors needed to satisfy the CMA requirement CMA A x LF x K AVD where CMA Cross section of wire in circular MIL area A Ultimate drain in amps LF Conductor loop feet K 11 1 constant factor for commercial TW type copper wire AVD Allowable voltage drop Check again that the ampacity rating of the cable meets the requirement for the installation application Consult local electrical codes NEC CEC etc for guidelines If required increase the size
13. defects or other reproductive harm e Battery post terminals and related accessories contain lead and lead compounds Wash your hands after handling batteries WARNING Follow battery manufacturer s safety recommendations around battery systems Do not smoke or introduce an open flame when batteries especially vented batteries are charging When charging batteries vent hydrogen gas which can explode e Batteries are hazardous to the environment and should be disposed at a recycling facility Consult the bat tery manufacturer for recommended local authorized recyclers 9400011 J0 Rev A 2 Overview 2 1 Introduction This manual covers the features and installation of the CXDM E2 series 600A distribution modules E2 panel is a high density breaker panel used in central offices cable headends and data centers for ter tiary distribution applications The 2RU panel designed with a split bus offers the capability for up to 22 plug in breaker fuse positions in a 19 configuration Individual 600A buses allow for maximum utilization of distribution capacity The E2 offers options for remote monitoring of alarms and analog parameters via a CAN bus to a centralized con troller CXC HP or with IP SNMP connectivity 2 2 Features and Benefits High density remote distribution for Telecom CO s MSC s data center and cable headend facilities Industry leading system density High breaker density 11x plug in bullet bre
14. maximum access to the connections Although it is possible to make the connections with the bottom cover in place it is recommended that the feed connections to the E2 are made before adjacent equipment is installed With the cover open mount the lugs back to back on the input bus bars Place the nuts on the side that provides the greatest access for a ratchet Tighten the self locking nuts rather than the bolt no separate washers necessary Once the lugs are connected move the bottom cover into position and secure the middle of the cover first Figure 13 Lug Connection middle push clip with a single push clip The fasten at each end two total Connect the top cover to the bottom cover using the three 3 push clips along the back Affix the top to the side panels using the two push clips at the ends 9400011 J0 Rev A Figure 14 Back Cover Installation 7 3 3 Feed Connections using Vertical Adapter Kits For feeds coming from above use the vertical adapter kits P N These kits make it easier to dress the feed cables at varying angles while still maintaining clearance for attaching load cables 1 Addthe adapter plates to the input bus bars of the E2 When deciding which side of the input bus bar to mount the adapter plates refer to the tear out section of the top cover When mounted correctly the tear out Figure 15 Vertical Adapter Installation section is aligned with the adapter plate 2 Once the ada
15. safe place Re view the drawings and illustrations contained in this manual before proceeding If there are any questions regard ing the safe installation or operation of this product contact Innovative Energies 1 1 Safety Symbols To reduce the risk of injury or death and to ensure the continued safe operation of this product the following symbols have been placed throughout this manual Where these symbols appear use extra care and attention The use of ATTENTION indicates specific regulatory code requirements that may affect the placement of equipment and or installation procedures NOTE wi NOTE provides additional information to help complete a specific task or procedure Notes are designated with a checkmark the word NOTE and a rule beneath which the information appears AN CAUTION CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment Cautions are designated with a yellow warning triangle the word CAUTION and a rule beneath which the information appears WARNING e WARNING presents safety information to PREVENT INJURY OR DEATH to personnel Warnings are indicated by a shock hazard icon the word WARNING and a rule beneath which the information appears TA HOT HOT presents safety information to PREVENT BURNS to the technician or user 1 2 General Warning and Cautions Bad WARNING You must read and understand the following warnings before installing the enclosur
16. 00170 011 0200170 012 A OUTLINE DRAWING CXDM E2 TITLE 0200170 06 SIZE DWG NO 2 or 2 SHEET 1 1 SCALE Innovative Energies Ltd 1 Heremai Street Henderson NZ Tel 64 9 835 0700 info innovative co nz www innovative co nz Innovative Energies Lid 1 Heremai Street Henderson NZ Tel 64 9 835 0700 info innovative co nz www innovative co nz innovative energies Innovative Energies Ltd 1 Heremai Street Henderson NZ Tel 64 9 835 0700 info innovative co nz www innovative co nz
17. 2 positions per panel 11 breakers per bus 22 positions per panel Output Hot and Return 22 x 1 4 20 studs on 5 8 centers 22 x 1 4 20 studs on 5 8 centers 22 x 1 4 20 studs on 5 8 centers Lug Adaptors optional Double Pole Studs on 1 Centers Double Pole Studs on 1 Centers Double Pole Studs on 1 Centers Triple Pole Studs on 1 Centers Triple Pole Studs on 1 Centers Triple Pole Studs on 1 Centers Chassis Ground 1 4 studs on 5 8 centers 1 4 studs on 5 8 centers 1 4 studs on 5 8 centers Controls bus voltages via indicator board Alarms Breaker Fuse trip Form C Breaker Fuse trip Form C Breaker Fuse trip Form C contacis contacis contacis Monitor Breaker Fuse trip and Breaker Fuse trip and bus Breaker Fuse trip and voltages via CAN bus to CXC HP controller bus voltages on CXC HP controller IP SNMP LED Indicators System Ok Green Breaker Fuse Trip Red System Ok Green Breaker Fuse Trip Red System Ok Green Breaker Fuse Trip Red Environmental Temperature 0 to 40 C 0 to 104 F 0 to 40 C 0 to 104 F 0 to 40 C 0 to 104 F Humidity 0 95 non condensing 0 95 non condensing 0 95 non condensing Compliance CSA CSA C22 2 No 60950 1 UL 60950 1 CSA C22 2 No 60950 1 UL 60950 1 CSA C22 2 No 60950 1 UL 60950 1
18. SA C22 2 No 60950 01 and UL 60950 01 IE UPS products bearing the aforementioned CSA marks are certified to CSA C22 2 No 107 3 and UL 1778 As part of the reciprocal US Canada agreement regarding testing laboratories the Stan S pe dards Council of Canada Canada s national accreditation body granted Underwriters Labo ratories UL authority to certify products for sale in Canada 2 NRTL C Only Underwriters Laboratories may grant a licence for the use of this mark which indicates compliance with both Canadian and US requirements 3 NRTLs capabilities NRTLs are third party organizations recognized by OSHA US Depart ment of Labor under the NRTL program The testing and certifications are based on product safety standards OSHA developed by US based standards developing organizations and are often issued by the American National Standards Institute ANSI 4 The NRTL determines that a product meets the requirements of an appropriate consensus based product safety standard either by successfully testing the product itself or by verifying that a contract laboratory has done so and the NRTL certifies that the product meets the requirements of the product safety standard 4 NRTL Program Governance of NRTL NRTL The NRTL Program is both national and international in scope with Recognized foreign labs permitted Labs 1 www csagroup org 2 www scc ca 3 www ulc ca 4 www osha gov 9400011 J0 Rev A
19. ack orientation The landings are designed for the in put feeder cables to be installed horizontally optional adapters recommended are available for the input feeder cables to be installed vertically with a slot that allows the cables to be angled backwards up to 30 degrees The base system cover opens easily to make connections and can be re closed using snap clips Additional lug and adapter covers are included with the vertical adapter kits Load Connections Return Connections Feed and Ground Connections under cover Bus A Bus B Figure 3 Feed Connections 9400011 JO Rev A 10 4 3 Load Connections The system has a total of 22 load connections divided into a split bus for both hot and return Both connections are front accessible when the unit is installed with a minimum of 2RU space above The connections are pro tected by a cover to prevent objects from falling into connecting area A separate cover also protects the breaker area and can be left in place while connections are made The load hot connections are located closest to the front for easy access and are separated by dividers to pre vent accidental contact with potentially live connections CAUTION ee The load connections being added should not have a breaker or be live when the cable is installed The load return connections are located behind and below the load hot connections allowing the two cables to be routed together to minimize any current
20. akers or TPS TLS fuses per bus High current density each bus is rated for a maximum amperage of 600A Split bus design provides redundant input feeds to network equipment 2RU height recovers space in network bays for revenue generating equipment Front panel control options standard enhanced I O interface advanced controller Adaptor kits available to accommodate vertical feeds Adaptor kits available for 2 pole and 3 pole breakers Figure 1 CXDM E2 600A Distribution 9400011 JO Rev A 3 Specifications For the E2 part numbers and list options go to the Innovative Energies website Table A Specifications Standard CAN Bus Monitoring IP SNMP Monitoring Nominal Voltage 48V 48V 48V Bus Capacity 600A per Bus 600A per Bus 600A per Bus 3 5 Hx 19 W x 12 D 89mm x 483mm 305mm 3 5 H x 19 W x 12 D 89mm x 483mm 305mm 3 5 H x 19 W x 12 D 89mm x 483mm 305mm Dimensions Excludes mounting Excludes mounting Excludes mounting brackets brackets brackets Mountin 19 23 w 1RU adaptor 19 23 w 1RU adaptor 19 23 w 1RU adaptor 9 flush or center default flush or center default flush or center Weight TBD TBD TBD Connections Input Hot and Return 2 x 3 8 mounting holes on 1 centers 2 x 3 8 mounting holes on 1 centers 2 x 3 8 mounting holes on 1 centers Positions 11 breakers per bus 22 positions per panel 11 breakers per bus 2
21. ble voltage drop Check again that the ampacity rating of the cable meets the requirement for the installation application Consult local electrical codes NEC CEC etc for guidelines If required increase the size of the cable to meet the code 7 4 2 Load Planning Breaker fuse Spacing The E2 current rating of 1200A 600A per bus continuous enables very dense power distribution in a 2RU 19 rack volume Effective management of heat is critical to such systems and the E2 buswork and ventilation is designed to both minimize heat generation but also extract and dissipate the heat generated by the breakers or fuses Because breakers fuses generate most of the heat in a system care must be taken in the layout of high current breakers fuses Specifically the guidelines are as follows 1 Any single pole Over Current Protection Device OCPD rated at 100A and above can be mounted in pairs but cannot have an OCPD installed on either side of the pair 2 Any single pole Over Current Protection Device OCPD rated at 90A can be mounted in triples but cannot have an OCPD installed on either side of the triple 3 Any single pole Over Current Protection Device OCPD rated at 80A and below can be mounted in any position without spacing While these guidelines require some planning they do not limit achieving the 600A side capacity for any breaker size combination except if many small breakers are used Below are example layouts which may show
22. d for service it should be packaged in its original shipping container If the original container is unavailable make sure that the product is packed with at least three inches of shock absorbing material to prevent shipping damage Innovative Energies is not responsible for damage caused by improper packaging of returned products 5 2 Check for Damage Before unpacking the product note any damage to the shipping container Unpack the product and inspect the exterior for damage If any damage is observed contact the carrier immediately Continue the inspection for any internal damage In the unlikely event of internal damage inform the carrier and contact Innovative Energies for advice on the impact of any damage 5 3 General Receipt of Shipment The inventory included with your shipment depends on the options you have ordered The options are clearly marked on the shipping container labels and bill of materials 9400011 JO Rev A Innovative Energies Ltd 1 Heremai Street Henderson NZ Tel 64 9 835 0700 info innovative co nz www innovative co nz 17 18 6 Installation Only qualified personnel should install and connect the power components within the IE system For the battery installation refer primarily to the manufacturer s manual 6 1 Safety Precautions Refer to the Safety section near the front of this manual 6 2 Tools Required Various insulated tools are essential for the installation Use this list as a guide
23. e and its component Failure to do so could result in personal injury or death e Read and follow all instructions included in this manual e Only trained personnel are qualified to install or replace this equipment and its components e Use proper lifting techniques whenever handling equipment parts or batteries 9400011 JO Rev A 1 3 Electrical Safety WARNING Hazardous voltages are present at the input of power systems The DC output from rec tifiers and batteries though not dangerous in voltage has a high short circuit current capacity that may cause severe burns and electrical arcing Before working with any live battery or power system follow these precautions a Remove all metallic jewelry such as watches rings metal rimmed glasses or necklaces b Wear safety glasses with side shields at all times during the installation C WARNING Use OSHA approved insulated hand tools Do not rest tools on top of batteries Lethal voltages are present within the power system Always assume that an electrical connection or conductor is energized Check the circuit with a voltmeter with respect to the grounded portion of the enclosure both AC and DC before performing any installa tion or removal procedure Do not work alone under hazardous conditions A licensed electrician is required to install permanently wired equipment Input voltages can range up to 240 Vac Ensure that the utility power is disconnected
24. gle ala se ale al aa EI Fle Ale Fl d 24 Se 53 2 a2 ad ai lt lt YH NI RETURN FEED A HOTFEED A Cordex L ADIO 0180039 XXX J100 rm e a mm zm em eK LIST 713 Add CXCHP CONTROLLER to LIST 712 J101 TB508 2 38 TB301 2 40 TB301 1 41 cc am ae am am em em a ae a am a am am ae ae ae am am am ae a a ae ae am am ae em em ae ae am e e em em em am e e ae ae am em ama em am ce am al RED wire for 48V 24V BLACK wire for 48V 424V gt RED wire for 48V 24V BLACK wire for 48V 24V 5380044 LEFT SIDE FACING FRONT To Ground Stud on Panel Cordex HP Controller 0180036 XXX GND aan aaa aa QE KE oe alla E2 E3 Indicator BoardA JE A LEFT SIDE FACING FRONT CUSTOMER CONNECTIONS VA_SNS VA_SNS PWR_A lt PWR_A VA_SNS VA_SNS Trei CHASSIS Connection through mounting screw 8700789 001 A 8700766 001 A PWR_A gt t TIE 2 CXDS E2 Distribution Center e gt Universal System Schematic BATE SHEET 1 of 1 SIZE TYPE DWG NO REV B s5 0200170 05 B 5 4 a 17 33 lt 17 13 a PA EPE pk 070585 36 593 a oo Sgt 8 20 stele i 2208 VOS SC Dad e pento da dg 305959 92 a2 sto 99595 KE SE ER 12 40 3 DO NOT SCALE DRAWING _ 19 00 0200170 001 0200170 002
25. how to best accomplish 600A capacity with the largest size of breakers 7 4 3 Load Connections For wire sizing refer to guidelines supplied with the load equipment Terminate distribution cabling with 1 4 5 8 center lugs for connecting to E2 Always make the return connection to the E2 and then verify the nut tightening torque before installing the hot connection as once the hot connection is in place it is difficult to access the return connection Always use the supplied hardware nuts for attaching the lugs The supplied nuts have a serrated flange which eliminates the need for a second lock washer both allowing more threads to show after a completed connection and avoiding thin hardware which can fall through small gaps in the equipment covers Load Breaker Return Connections NOTE Connect load breaker returns before hot connections 1 Secure cables with two hole lugs to the 1 4 studs on 5 8 centers using the supplied hardware 2 Runcables directly out the rear of the distribution center 9400011 JO Rev A 25 Load Breaker Hot Connections Connect load breaker hot connections 1 Secure cables with two hole lugs to the 1 4 studs on 5 8 centers using the supplied hardware 2 Run cables directly out the rear of the distribution center above the breaker return cables Make Hot m a F Connection Second te To amp Make Return mmm Connection First Figure 18 Battery load and return connection locations with ba
26. ing both web and SNMP interfaces The CXC HP supports dual CAN ports to allow up to 254 power and or ADIO modules to be controlled and monitored The CXC HP uses external analog and digital input and output ADIO peripherals to monitor electrical signals temperature voltage temperature and generate electrical signals through relays The most commonly used ADIO peripheral is the L ADIO for low voltage systems which includes e 8 digital inputs e 4voltage sensors e 4temperature sensors e 4current sensors e 12 Form C relay outputs LEDs LCD Ethernet rear gt BEMI aaa A vn e e _ x_ Touchscreen USB rear _ e e _ gt L re Home Button bd eg nt eg Ae i i n Reset Button USB front Ethernet front Figure 8 CXC HP controller front left view 9400011 J0 Rev A Replaceable RTC Lithium Battery gt nine ni az CAN Ports Controller Fail lt Alarm Relay lt Power Input Figure 10 CXC HP controller right top view The CXC HP has the following features Front touchscreen full color LCD touchscreen display to access controls and menu items by using fingertip touch or a stylus Home button provides the ability to go directly back to the home screen from any menu Front panel reset for emergency use only to restart the CXC HP if the unit touch screen or home button are not responding Front panel LEDs for alarms progress and sta
27. ional area MOV Metal oxide varistor MTBF Mean time between failures NC Normally closed NEC National Electrical Code for the USA NO Normally open OSHA Occupational Safety amp Health Administration OVP Over voltage protection RAM Random access memory RU Rack unit 1 757 TCP IP Transmission Control Protocol Internet Protocol THD Total harmonic distortion UL Underwriters Laboratories VRLA Valve regulated lead acid 9400011 JO Rev A 31 11 Certification About CSA and NRTL CSA Canadian Standards Association also known as CSA International was established in 1919 as an independent testing laboratory in Canada CSA received its recognition as an NRTL Nationally Recognized Testing Laboratory in 1992 from OSHA Occupational Safety lt pe and Health Administration in the United States of America Docket No NRTL 2 92 This was expanded and renewed in 1997 1999 and 2001 The specific notifications were posted on C US OSHA s official website as follows e Federal Register 59 40602 40609 08 09 1994 e Federal Register 64 60240 60241 11 04 1999 e Federal Register 66 35271 35278 07 03 2001 When these marks appear with the indicator C and US or NRTL C it means that the C US product is certified for both the US and Canadian markets to the applicable US and Cana dian standards 1 IE rectifier and power system products bearing the aforementioned CSA marks are certified to C
28. ious types of electrical signals Some of the analog channels are reserved for specific signals while others are designated as general purpose inputs that accommodate vari ous types of analog signals Voltage Temperature Current Inputs See the front panel descriptions under section 4 Features 9400011 JO Rev A 8 Maintenance Although very little maintenance is required with Innovative Energies routine checks and adjustments are recommended to ensure optimum system performance Qualified service personnel should do the repairs The following table lists a few maintenance procedures for this system These procedures should be performed at least once a year Use extreme care when working inside the unit while the system is energized Do not make contact with live components or parts Circuit cards including semi conductor devices can be damaged by static electricity Always wear a grounded wrist strap when handling or installing circuit cards Ensure redundant modules or batteries are used to eliminate the threat of service inter ruptions while performing maintenance on the system s alarms and control settings Table B Sample maintenance log Procedure Date Completed Clean ventilation openings Il Inspect all system connections Re torque if necessary RE Verify alarm control settings rr Verify alarm relay operation 9400011 JO Rev A 30 9 Warranty and Service Information 9 1 Technical Support F
29. lays will de energize when the controller reset button is pressed or when the power is lost CAUTION To reduce risk of fire use only 26 AWG 0 129 mm2 or larger wire NO Cc NC Normally Common Normally Open Closed 9400011 J0 Rev A 27 AN 28 7 8 2 Digital inputs for controller The factory installed digital input channels are used to monitor various alarm and control signals All input chan nels are voltage activated and directly accept a bipolar negative or positive DC signal Connection Method Typical Innovative Energies use a reset with Hot and trigger with Ground connection The digital input is wired so that Hot is wired directly into one of the input terminals e g negative input for 48 V systems The other input terminal is wired to the common ground of the system through a relay which is a dry contact usually located on the equipment that requires monitoring This method allows the digital input to receive or not receive a Ground signal during an alarm See Figure 11 Programming the Digital Input The digital input channels can be programmed for active high or active low Active high indicates an alarm when a ground signal is present Active low indicates an alarm when the ground signal is removed See the con troller software manual 7 8 3 Analog Inputs CAUTION Ensure that the correct polarity is used for all input cable terminations The analog input channels are used to monitor var
30. loops Studs are provided for both hot and return connections to simplify alignment The insulation covers below the connection area prevent any dropped hardware from entering into the buswork area of the system The load positions are identified by a label located along the top of the breakers fuses There is also a second label located on the top of the front door for describing the load of each breaker fuse and is accessible when the door is open Door Latches Door Latches Bus B Breaker Alarm Bus A Indicators Breaker Alarm Indicators Bus A Bus B Figure 4 Front Panel 9400011 J0 Rev A 4 4 Monitoring Methods The E2 is available with three different front panels that provide increasing levels of inputs and outputs I O and control standard enhanced I O and advanced controller All panels have the basic features such as alarm indi cators door latches and top label as shown in Figure 4 below The standard front panel includes two indicator circuit boards one for each bus located at the corresponding end of the panel Each indicator board receives power and signals through a single cable which connects to the breaker alarm strip in the core of the E2 The indicator boards also act as an interface to the LADIO module and CXC HP controller in the more advanced panel versions Feature Standard CAN Bus Monitoring IP SNMP Monitoring LED indicator Bus Power Present Breaker Alarm 2 Dedicated I O Bus Voltage
31. of the cable to conform to the code 7 3 DC Output Connections AnA Leave the cables or bus bars disconnected at the load and verify the output polarity us ing a voltmeter Make the connections only after this verification DC output wire must be UL approved XHHW or RHH RHW RW90 type for Canadian users Control and sense wires must be UL approved Style 1015 TEW type for Canadian users Terminate the cable leads with appropriate crimp lugs Secure the positive and negative DC output cables to the unit s output post of the correct polarity i e Vcable to Vpost Ensure that the washers are placed on the bolts in the same order in that they were shipped from the factory 7 3 1 DC Input Connection ROUS Ensure that the correct polarity is used for all cable terminations The E2 is rated for a maximum 600A per bus and the input connections are sized to accept up to 2 x 750 MCM per bus All cables should be routed carefully and secured to the ladder rack or frame so that there is limited stress on the E2 connections themselves 9400011 JO Rev A 21 22 7 3 2 Standard Horizontal Feed Connections Up to 750 MCM sized lugs can be directly connected to the each input bus bars of the E2 These connections are accessible through the back cover and are arranged as shown in Figure 12 Bus A Bus B Figure 12 Horizontal Feed Connections Open the unit cover fully With bottom cover hanging vertically there is
32. ored by the L ADIO and can be read by a remote CXC HP controller through the CAN bus connection The L ADIO also provides expansion I O capability including two analog voltages V3 V4 four thermocouples T1 T4 12 dry contact relays K1 K12 six digital inputs D3 D8 Please refer to the hardware manual 0180036 JO for specifications of these inputs as well as the front panel wiring notes below for guidance on L ADIO wire routing 9400011 JO Rev A Bus B Voltage lt Bus A Voltage 3 em M R CXC HP LADIO BT ka CAN Poris SCS SOG SES GSS SES 0000400 OF CS He OF ETETETT A AA Power Input Bus A Alarm Bus B Alarm Figure 7 L ADIO I O Peripheral 4 6 1 Analog Input Channels The controller is supplied with analog input channels for voltage current and temperature 4 6 2 Voltage Inputs Two voltage input channels V1 and V2 are used to monitor the discharge and charge voltage V1 for Bus A Volt age and V2 for Bus B Voltage Voltage inputs V3 and V4 are not used in the E2 and are available for customer use 4 6 3 Temperature Inputs The E2 panel can accept up to four temperature probes to monitor the surrounding ambient temperatures These analog values can be used to report high orlow temperature alarms 4 6 4 Digital Input Channels The E2 panel can accept up to eight digital inputs Digital Inputs D1 and D2 are wired for Bus A Breaker Alarm and Bus B Breaker Alarm res
33. pectively Digital inputs D3 to D8 are available for customer use 4 6 5 Alarm and Control Output Relays The controller contains 12 Form C digital alarm output relays that are used to extend alarms and control to ex ternal apparatus Each internally generated alarm or control signal may be mapped to any one of these relays or several signals may be mapped to just one relay or none at all None of the output relays are pre configured on the K1 K12 are available for customer use 4 6 6 Network Connection and Remote Communication A CAN bus is used to transmit all alarm and control functions between the LADIO and a remotely located CXC HP controller 9400011 J0 Rev A 13 4 7 FrontPanel with a CXC HP Controller The front panel with CXC HP controller also includes the LADIO module with all of the features described in sec tion 4 6 above With this version the L ADIO CAN Bus is pre wired to the local CXC HP controller Detailed operation of the controller is provided in the CXC HP controller software manual The CXC HP family of products provide centralized setup control and monitoring of power systems This can range from simple monitoring and threshold alarms for temperature voltage and current to advanced battery charging and diagnostic features The controller has a 4 3 inch full color touch screen display The CXC HP provides dual Ethernet ports allowing for simultaneous network LCD and local laptop access to the controller includ
34. pter plate is mounted attach the bottom cover to the frame using the instructions from 7 3 2 3 Tear out the narrow section of the top cover to fit around the adapter plate and attach the top cover to the 9400011 JO Rev A 23 NOTE Before applying power to the unit ensure that the bottom of the adapter plate is insu lated from any equipment that may be mounted below and ensure that all covers are in place Figure 16 Vertical Adaptor Closed bottom cover and to the side panels using the instructions from 7 3 2 4 Once the cover is in place connect the lugs to the adapter plate at an angle that is most convenient for cable routing 5 Check that there is no excessive force from cable weight or stiffness to the input bus bars Cables should be externally supported to avoid undue stress being transferred from the cable to the E2 Figure 17 Lugs Mounted to Vertical Adapter 24 9400011 JO Rev A 7 4 Distribution Cabling 7 41 Calculating Output Wire Size Requirements Wire size is calculated by first determining the appropriate maximum voltage drop requirement Using the formula below calculate the CMA wire size requirement Determine the size and number of conductors required to satisfy the CMA requirement CMA A x LF x K AVD where CMA Cross section of wire in circular mil area A Ultimate drain in amps LF Conductor loop feet K 11 1 constant factor for commercial TW type copper wire AVD Allowa
35. re possible to make routing easier and to minimize space consumed by in the system This is especially important with the L ADIO if many of the expansion I O capabilities are to be used Added wiring should be routed along the same path as the bus connection cable and then extend through the back of the unit Take care to restrain the wiring sufficiently while providing enough slack so as not to interfere with operation of the door Use the cable tie locations on the L ADIO to restrain the cables within the front panel and use the lance features on the chassis side panels to guide the cabling to the back of the unit 9400011 J0 Rev A 5 Site Evaluation and Pre Installation 5 1 Packing Materials IE is committed to providing products and services that meet our customers needs and expectations in a sustainable manner while complying with all relevant regulatory requirements As such IE strives to follow our quality and environmental objectives from product supply and development through to the packaging for our products Packaging assemblies and methods are tested to International Safe Transit Association standards Rectifiers and batteries are shipped on individual pallets and are packaged according to the manufacturer s guidelines Almost all of Innovative Energies packaging material is from sustainable resources and or is recyclable 5 1 1 Returns for Service Save the original shipping container If the product needs to be returne
36. ree Technical Support 24 7 365 is part of the IE customer satisfaction commitment The phone numbers below can also be used to access a wide range of service solutions Phonel 64 9 835 0700 info innovative co nz 9 2 Warranty From the date of shipment from the factory The warranty provides for repairing replacing or issuing credit at IE discretion for any equipment manufactured by it and returned by the customer to the factory or other autho rized location during the warranty period There are limitations to this warranty coverage The warranty does not provide to the customer or other parties any remedies other than the above It does not provide coverage for any loss of profits loss of use costs for removal or installation of defective equipment damages or consequential damages based upon equipment failure during or after the warranty period No other obligations are expressed or implied Warranty also does not cover damage or equipment failure due to cause s external to the unit including but not limited to environmental conditions water damage power surges or any other external influence The customer is responsible for all shipping and handling charges Where products are covered under warranty Innovative Energies will pay the cost of shipping the repaired or replacement unit back to the customer 9 3 Return of Material Please contact Technical Support at the number above to obtain a Service Repair Order or Return Material A
37. ttery and load breakers shown 7 5 Alarm and Signal Connection 7 5 1 Breaker Alarm and Bus Voltage Connections 1 Locate the terminal block on the rear of the CXDM E2 Refer to Figure 9 and the schematic drawing at the end of this manual for details on terminal block assignments 2 Connect these alarms and signals to the local alarm sending unit Use wire sizes 20 to 26 AWG 0 518 to 0 14mm Bus A Bus A Bus B Bus B Voltage Voltage Voltage Voltage A I 4 Bus A Breaker Bus B Alarm NC Breaker Alarm NC Bus A Breaker a las Bus B Alarm COM mt Breaker Alarm COM Bus B Breaker Alarm NO Bus A Breaker Alarm NO Left Bus A Connection Right Bus B Connection Figure 19 Battery load and return connection locations with battery and load breakers shown 26 9400011 JO RevA 7 6 CAN Serial Ports The CAN serial port s are located on the front of the L ADIO and on the side of the controller and are clearly labelled CAN serial ports are modular jacks with offset latches that are used to communicate with the rectifiers and other CAN enabled equipment nodes on the same system For more detailed information on CAN refer to the Reference section in the software manual 0350058 JO 7 6 1 CAN Termination A CAN termination jumper is located beside each of the CAN serial port jacks on the rectifier shelves See the customer connection drawing and schematic that describes your system
38. tus indication Audio speaker built in audio speaker tones during active alarms and can be disabled if required Ethernet dual ports 10 100BASE T Ethernet connection on both the front and rear of the controller for remote or local communication USB dual ports on both the front and rear of the controller for upgrades or file management via a standard USB flash drive CAN dual independent CAN bus ports for communication with the Cordex and AMPS family of products allowing for a greater number of devices Real time clock with field replaceable lithium battery allows for timestamps on alarms and events System fail alarm relay which activates when there is a major internal failure During such a condition the unit attempts to reset V CA No Alarms Unknown AOL a Figure 9 CXC HP controller touchscreen display Controller 9400011 JO Rev A 15 16 4 7 1 Network Connection and Remote Communications The Cordex system can be set up monitored and tested via an Ethernet 10 100 Base T serial data connection The communication protocol supports a web interface A CAN bus is used to transmit all alarm and control func tions between the controller and rectifiers Refer to CXC HP Software Manual 0350058 J0 for operation of controller 4 7 2 Front Panel Wiring Notes The terminal blocks on the Indicator Boards are suitable for 26 16AWG wire As both signals are low current it is recommend to use thinner wire we
39. utho rization number BEFORE sending material back This will ensure that your service needs are handled promptly and efficiently 9 4 Service Centers For a list of service centers refer to the Innovative Energies website http www innovative co nz 9400011 J0 Rev A Innovative Energies Ltd 1 Heremai Street Henderson NZ Tel 64 9 835 0700 info innovative co nz www innovative co nz 10 Acronyms and Definitions AC Alternating current ANSI American National Standards Institute AWG American Wire Gauge BTU British thermal unit CAN Controller area network CEC Canadian Electrical Code CSA Canadian Standards Association CX Cordex series e g CXC for Cordex System Controller DC Direct current DHCP Dynamic Host Configuration Protocol EIA Electronic Industries Alliance EMC Electromagnetic compatibility EMI Electromagnetic interference ERM Electromagnetic Compatibility and Radio Spectrum Matters ESD Electrostatic Discharge FCC Federal Communications Commission for the USA GSM Group Speciale Mobile global system for mobile communications HVSD High voltage shutdown IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IP Internet Protocol LED Light emitting diode LVD Low voltage disconnect MIL One thousandth of an inch used in expressing wire cross sect
40. wo terminal block connectors that provide connections to a Form C dry contact for the breaker alarm and to connection terminals for monitoring bus voltage which can be wired to 3rd party monitor ing equipment The terminal blocks can be accessed when the door is open The status of each bus can also be monitored by wiring to outputs on the indicator boards A 2 position screw type terminal connector makes the bus voltage available This is a non isolated fused signal intended for connec tion to a high impedance input A 3 position screw type terminal connector makes the breaker status available through connection to a dry contact relay Bus A Bus A Bus B Bus B Voltage Voltage Voltage Voltage A 4 4 Bus A Breaker Bus B Alarm NC lt Breaker Alarm NC Bus A Breaker _ Bus B Breaker Alarm COM Bus B Breaker Alarm NO Alarm NO Left Bus A Connection Right Bus B Connection Figure 6 Left and Right side Connections 4 6 Front Panel with Enhanced 1 0 The front panel with enhanced UO includes the components and functionality of the standard front panel with the addition of a Large Analog Digital Input and Output L ADIO module and a cable harness that connects it to the indicator boards The L ADIO module is powered by both the A and B bus via the indicator boards and will continue to operate even if one of the bus is not powered The breaker alarm status and voltage level of each bus is monit
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